Dual-Density Foam Pillow for Neck Support and Head Softness

Solution Overview

Problem

Conventional pillows either fail to provide adequate support for the neck and shoulders due to being too soft or are undesirable for the head due to being too firm, as they often compromise between softness and support.

Innovation Solution

A dual density molded foam pillow with a denser outer portion for neck and shoulder support and a less dense interior portion for head softness, produced using a foam molding system with varying foam precursors to achieve specific density and hardness levels, and optionally featuring ergonomic design elements like recessed interiors and divots for enhanced comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a pillow is made soft to cradle the head, then the feeling of softness is improved, but the support for the neck and shoulders deteriorates

Engineering Contradiction:

Improvefeeling of softnessVSAvoidsupport for neck and shoulders

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies local quality by creating different density zones within the pillow - a less dense interior portion (0.02-0.06 g/cc) for head softness and a denser outer portion (0.06-0.12 g/cc) for neck and shoulder support. This allows each region to have optimized properties for its specific function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining foam layers of different densities and potentially different foam types (memory foam, latex, polyurethane) to create a multi-layered structure that provides both softness and support simultaneously.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a pillow is made firm to support the neck and shoulders, then the support is improved, but the softness for the head deteriorates

Engineering Contradiction:

Improvesupport for neck and shouldersVSAvoidfeeling of softness

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent applies local quality by creating different density zones within the pillow - a less dense interior portion (0.02-0.06 g/cc) for head softness and a denser outer portion (0.06-0.12 g/cc) for neck and shoulder support. This allows each region to have optimized properties for its specific function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining foam layers of different densities and potentially different foam types (memory foam, latex, polyurethane) to create a multi-layered structure that provides both softness and support simultaneously.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If a pillow uses uniform density foam, then the manufacturing process is simplified, but the ability to provide both softness and support deteriorates

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidability to provide both softness and support

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by creating different density zones within the pillow - a less dense interior portion (0.02-0.06 g/cc) for head softness and a denser outer portion (0.06-0.12 g/cc) for neck and shoulder support. This allows each region to have optimized properties for its specific function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining foam layers of different densities and potentially different foam types (memory foam, latex, polyurethane) to create a multi-layered structure that provides both softness and support simultaneously.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The dual density design provides both support for the neck and shoulders and softness for the head, accommodating user preferences and comfort, while the foam molding process ensures efficient production of pillows with tailored properties.

Implementation Method 1

a first foam precursor is then dispensed into a central portion of the bottom mold. After the first foam precursor is dispensed into a central portion of the bottom mold, a second foam precursor is then dispensed into a peripheral portion of the mold

Methodology Applied

Scientific EffectFoam expansion and setting:

Implementation Method 2

the interior portion and the outer portion are comprised of a flexible foam (e.g., a visco-elastic foam) with the density of the interior portion being less than the density of the outer portion

Methodology Applied

Scientific EffectVisco-elastic deformation: Viscoelasticity

Data Source

PatentEP3200658B1Dual density molded foam pillow

Publication Date: 2020.05.27 TEMPUR WORLD LLC

Figure 3
Figure 4
Figure 7

AI summary

A pillow includes an inferior portion and an outer portion. The interior portion is comprised of a first flexible foam, while the outer portion is comprised of a second flexible foam having a density different than that of the first flexible foam. Methods of producing a pillow are also provided whereby either a first foam precursor is dispensed into a central portion of a mold to provided a first flexible foam, or a pre-formed foam insert comprised of a first flexible foam is placed into a central portion of a mold. A second foam precursor is then subsequently dispensed into a peripheral portion of the mold to produce a second flexible foam having a density different than that of the first flexible foam. Upon reaction and expansion of the foam precursors, a molded foam pillow is produced having dual densities.